Core block door construction



Feb. 11, 1958 J. w. HAYNES CORE BLOCK DOOR CONSTRUCTION Z SheetS-Sheet 1Filed Oct. 5, 1954 INVENTOR.

F4 JJ l Jami/I 5 w n A .1 a W W A f 3 d, r J a & 2 J/WW nm K 4 Z N J MFeb. 11, 1958 J. w. HAYNES 2,822,870

CORE BLOCK DOOR CONSTRUCTION Filed Oct. 5, 1954 2 Sheets-Sheet 2 UnitedStates Patent CORE BLOCK DOOR CONSTRUCTION John W. Haynes, Susanville,Calif.

Application October 5, 1954, Serial No. 460,327

1 Claim. (Cl. 160-380) This invention relates to the construction ofdoors wherein core blocks, such as of wood, are secured by a suitableadhesive between layers of veneer with combinations of wood panels andwire screens positioned between stiles and top, bottom and lock rails,and in particular, an improved door assembly wherein blocks are securedby glue or a suitable adhesive between sheets of veneer with openingsfor panels and wire mesh between the stiles and top, bottom and lockrails in which the parts are secured in assembled relation withoutboring holes for dowel pins or without using other fastening elements.

The purpose of this invention is to provide an assembly of core blocksand veneer panels wherein the parts are secured together and panels orlayers of wire mesh are secured in openings between the stiles, top,bottom and lock rails without the use of moulding, beads and coves orother finishing or fastening elements.

In the conventional manner of forming a door of this type, the beads andcoves are formed in moulding machines and a slot is left for the veneerand, in numerous instances, the veneer is a little undersized wherebythe panels made from the veneer are loose. In some instances, the veneeris oversized and, in such cases, the bead is broken. Furthermore, inorder to start panels into the grooves, the panels are buffed off on twoedges and in such cases the panels are loose.

With this thought in mind, the improved door construction of thisinvention provides means for assembling panels and wire mesh in thestructure of the door so that it is not necessary that the panels beedged or bufied and, should the veneer be a little undersized oroversized, small strips secured to the core blocks between the veneerpanelsare adapted to take up variations in size making it possible toobtain tight panels.

The object of this invention is, therefore, to provide means formanufacturing a door in which the use of dowel pins, mortise and tenonedjoints and miter joints is eliminated.

Another object of the invention is to eliminate, in the construction ofa door, the bead and cove assemblies where the stiles, rails and muttinsjoin together.

Another object of the invention is to eliminate the necessity for edgingand bufling panels in door structures and thereby obviate loose panels.

A further object is to eliminate the use of moulding to secure wire meshto screen doors.

A still further object is to provide an improved core block doorassembly in which wire mesh layers and panels are rigidly secured in thestructure of a door and in which mortise and tenoned joints and dowelpins are eliminated in which the door is of a comparatively simple andeconomical construction.

With these and other objects and advantages in view, the inventionembodies a door including core blocks secured by a suitable adhesivebetween veneer panels with openings through the structure providing top,bottom and lock rails and with strips adapted to extend along the inneredges of the stiles and upper and lower edges of the rails for rigidlysecuring panels and the like in said openings.

Other features and advantages of the invention will appear from thefollowing description taken in connection with the drawings, wherein:

Figure 1 is a front elevational view illustrating a complete doorassembly with parts of the veneer on a lower corner of the door brokenaway to show the core block structure where the lower ends of the stilesare joined to the lower rails.

Figure 2 is a vertical section through the door taken on line 2-2 ofFigure l with the parts shown on an enlarged scale and with parts brokenaway.

Figure 3 is a sectional plan through one side of the door taken on line33 of Figure 1 also with the parts shown on an enlarged scale and withparts broken away.

Figure 4 is a view similar to that shown in Figure 1 with the veneer onthe near side of the door omitted and with parts broken away.

Figure 5 is a detail showing an exploded view of the door assemblyshowing the parts at the lower portion of the door with the upper partof the door broken away, said section being taken substantially on line55 of Figure 4.

Figure 6 is an exploded view illustrating the connections of the top,bottom and lockrails to the stiles and also the arrangement of thestrips in the panel and screen openings through the doors with partsbroken away.

Figure 7 is a detail showing a sectional plan, similar to that shown inFigure 3, showing a panel in the lower part of the door positionedbetween moulding strips and with parts broken away.

Referring now to the drawings, wherein like reference characters denotecorresponding parts, the improved core block door construction of thisinvention includes a plurality of core blocks 10 positioned to formstiles 11 and 12, a top rail 13, a bottom rail 14 and a lock rail 15,strips 16 and 17 secured to outer edges of the stiles 11 and 12, strips18 and 19 secured to the inner edges of the stiles in an opening 20between the top rail 13 and lock rail 15 with a strip 21 positionedagainst the inner surface of the top rail and a strip 22 positionedagainst the inner surface of the lock rail, strips 23 and 24 positionedon the inner surfaces of the stiles in an opening 25 for a panel 26positioned between the lock rail 15 and bottom rail 14 with strips 27and 28 on the inner surfaces of the rails 15 and 14, respectively, alayer of wire mesh 29 positioned between a veneer panel 30 and the coreblocks on one side of the door and a veneer panel 31 positioned on theopposite side of the door.

In the improved door construction of this invention, the core blocks 10,which are in the form of bricks and which are staggered, such as bricksin a wall, are assembled to form the stiles, top, bottom and lock railsof a door, the core blocks being secured together with an adhesive andwith the blocks in position the side surfaces are covered with veneerpanels or strips which are also secured to the surfaces of the coreblocks with a suitable adhesive.

By this means, the edges of the wire mesh 29 are adapted to extendupwardly to the point 32 and downwardly to the point 33 with the edgesat the sides or on the stiles extended to points, such as the point 34,shown in Figure 3 whereby, instead of securing the wire mesh with narrowstrips at the edges, comparatively wide portions, such as 1% inch stripsextend into the structure of the door whereby the wire mesh is firmlygripped. The inner edges of the stiles and top and lock rails are facedwith the strips 18, 19, 21 and 22 which extend continuously around theopening 20, and by this means, a finished portion is provided in theupper part of the door structure.

In the same manner, strips 23, 24, 27 and 28- are positioned against theinner edges of the stiles, lock and bottom rails in'the opening'25; andafter the-panel- 26-is in position, complementary strips; as indicatedby the numeral 35, are positioned between the panel 26 and veneer 31.

As illustrate'd'in Figured, thestiles'll and 1'2Tarepro= vided withnotches 36 and 37 for. receiving'theitop and bottom rails 13' and I4,respectively; and also notches 38 forreceivingthe'ends'of the lock rail15.

In the detail illustrated in Figure7'; coreblocks'40 are secured"between veneer panels'41t and 42 with a suitnhie adhesive, and with apanel" 43 mounted between strips 44 and 45, the outer edges 46 and 47,respectively, are rounded to provide finish strips; the roundingsurfaces blending with the inner edges of theveneer or surfacing panels.In this'design, thesides ofthe'stiles are provided with finish strips48,similar'to the strips I6 and' I7. It will be understood that th'e inneredges of the strips around the panels 26 and? Wire mesh 29 may beprovided with arcuate surfaces of different designs as may be desired.

It will also be understood that the" relative sizes ofthe' panels andWire mesh elements may be varied to provide different patterns and thenumber of the panels or openings for the wire mesh may also be varied tocornpensate for different conditions or styles of architecture.

It will be understood that other modifications; Within the scope of theappended claims; may" be made in the design and arrangement of the partswithout departing from the spirit of the invention.

What is claimed is:

A door construction comprising: a plurality of core blocks arranged toform stiles, top; bottom and lock rails, said stiles being provided withfirst notches for re"- ceiving portions of said top and bottom rails;said notches being arranged adjacent-the endsof the doo'nthere being asecond notch for receiving said lock rail, said second notch being"arranged between said first notches; said notches being shaped so thatthey snugly receive therein the coacting portions of the rails,finishing straps covering outer edges of the stiles, strips secured tothe inner edges of said stiles, top, bottom and lock rails, a layer ofwire mesh positioned between the stiles and top and lock rails withedges thereoffexten'ded over said strips and against the side surfacesof the core blocks, avpanel positioned between the stiles' and betweenthelock and bottom rails with edges thereof positioned between: saidstrips on the inner edges of the stiles and lock and bottom rails, andspaced parallel veneerpane'lspositioned to cover the side surfaces ofthecore blocksand strips and having openings therein positioned to registerwith openings for the wire mesh and first named panel, said core blocks,strips and veneer panels being secured together by means of an adhesive,said core blocks being of rectangular shape? and being arranged instaggered formation, said core blocks being ofirre'gul'arsizes; thecoreblocksforming said stiles having theirlongitudinal axes disposed invertical relation to each other'para'llel to the side edges of the doorand the core blocks of said top, bottom and lock rails being arranged inhorizontal relation and ar ranged parallelto the top and bottom edges ofthe door.

References'Cite'd" in the file of'thispaten't UNITED STATES PATENTSl',540;932 Dodge June 9,: 1925 2,020,644 Tesek Nov; 5, 1935 2,695,664Delegard et a1. Nov. 30, 1954;

